Komatsu CK25-1 Crawler Skid Steer Loader Workshop Service Repair Manual
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Complete & Official OEM Workshop Service Manual PDF Document
This Service repair manual offers detailed servicing instructions and will give you complete step by step information on repair, servicing,
preventative maintenance & troubleshooting procedures for your Komatsu Equipment.
This comprehensive service manual features photos and illustrations along with step-by-step instructions that will guide you through the entire repair process.
This manual contains all you need to know to keep your Komatsu machine working correctly.
You will find that this manual is a indispensable source of detailed maintenance and repair information and is the only service repair manual you will need for your Komatsu Equipment.
It will help you better understand, care for, service, and overall will lower the repair and maintenance cost for your Komatsu .
* PDF FORMAT
*Fully Bookmarked chapters for easy navigation allowing you to identify the exact service repair procedures in the quickest time possible.
*Detailed illustrations, exploded diagrams, drawings and photos guide you through every service repair procedure.
Models and Serial Numbers Covered :
CK25-1 - F00003 and UP
Table of Contents:
=========
S10. STRUCTURE AND FUNCTION....................................................................................... 10-1
P.T.O. ........................................................................................ 2
POWER TRAIN ......................................................................... 3
FRAME...................................................................................... 4
TRACK TENSIONER IDLER WHEEL ....................................... 5
TRACK TENSIONER CYLINDER AND BUMPER SPRING ..... 6
LOWER IDLER ROLLER .......................................................... 7
REAR IDLER ROLLER.............................................................. 8
HYDRAULIC CIRCUIT (STANDARD) ....................................... 9
HYDRAULIC CIRCUIT (FLOAT) ............................................. 10
HYDRAULIC CIRCUIT (FLOAT + PATTERN CHANGE)........ 11
HYDRAULIC CIRCUIT (HIGH-FLOW) .................................... 12
HYDRAULIC CIRCUIT (SUPER HIGH-FLOW)....................... 13
HYDRAULIC CIRCUIT (SUPER HIGH-FLOW / PATTERN
CHANGE)................................................................................ 14
HYDRAULIC PUMP ................................................................ 15
CONTROL VALVE (3-SPOOL) ............................................... 33
CONTROL VALVE (4-SPOOL) ............................................... 43
CLSS ....................................................................................... 47
SOLENOID VALVE ................................................................. 55
ACCUMULATOR..................................................................... 58
PATTERN CHANGE VALVE (OPTIONAL) ............................. 59
OPERATION ........................................................................... 61
R.H. PPC VALVE (STANDARD) ............................................. 62
R.H. PPC VALVE (PATTERN CHANGE) (OPTIONAL) .......... 66
L.H. PPC VALVE (STANDARD).............................................. 70
L.H. PPC VALVE - PATTERN CHANGE (OPTIONAL) ........... 74
EQUIPMENT CONTROL PPC VALVE.................................... 78
CYLINDERS............................................................................ 81
ELECTRICAL DIAGRAM (ENGINE LINE) (1/3) ...................... 83
ELECTRICAL DIAGRAM (ENGINE LINE) (2/3) ...................... 84
ELECTRICAL DIAGRAM (ENGINE LINE) (3/3) ...................... 85
ELECTRICAL DIAGRAM (FRAME LINE STANDARD) (1/3) . 86
ELECTRICAL DIAGRAM (FRAME LINE STANDARD) (2/3) . 87
ELECTRICAL DIAGRAM (FRAME LINE STANDARD) (3/3) . 88
ELECTRICAL DIAGRAM (FRAME LINE OPTIONAL) (1/3) ... 89
ELECTRICAL DIAGRAM (FRAME LINE OPTIONAL) (2/3) ... 90
ELECTRICAL DIAGRAM (FRAME LINE OPTIONAL) (3/3) ... 91
ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (1/5) .... 92
ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (2/5) .... 93
ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (3/5) .... 94
ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (4/5) .... 95
ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (5/5) .... 96
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (1/7)..... 97
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (2/7)..... 98
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (3/7)..... 99
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (4/7) ...100
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (5/7) ...101
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (6/7) ...102
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (7/7) ...103
ELECTRICAL DIAGRAM
(TOP-CABIN LIGHT LINE STANDARD) (1/2) ......................104
ELECTRICAL DIAGRAM
(TOP-CABIN LIGHT LINE STANDARD) (2/2) ......................105
ELECTRICAL DIAGRAM
(TOP-CABIN LIGHT LINE HOMOLOGATION) (1/2) .............106
ELECTRICAL DIAGRAM
(TOP-CABIN LIGHT LINE HOMOLOGATION) (2/2) .............107
20. TESTING AND ADJUSTING ........................................................................................... 20-1
NORMAL OR STANDARD TECHNICAL DATA..............3
SPECIAL TOOLS..........................................................12
CHECKING THE ENGINE SPEED...............................13
ADJUSTMENT OF VALVE CLEARANCE ....................14
MEASUREMENT OF THE COMPRESSION
PRESSURE ..................................................................16
CONTROL AND ADJUSTMENT OF THE FAN
BELT TENSION............................................................17
CONTROL AND ADJUSTMENT OF THE
INJECTION TIMING......................................................18
CHECKING ENGINE OIL PRESSURE.........................20
ADJUSTING THE STROKE OF THE
ACCELERATOR CABLES............................................21
REGULATION OF PPC VALVES’ DRIVE PRESSURE22
ADJUSTMENT OF THE PPC VALVE CLEARANCES .24
ADJUSTING THE POSITION OF THE SERVOCONTROL
ENGAGEMENT SAFETY SENSOR.......... 25
CONTROL AND REGULATION OF THE PRESSURES IN
THE HYDRAULIC CIRCUITS ...................................... 26
TESTING THE HYDRAULIC PUMP............................. 27
VALVE CALIBRATION................................................. 28
CHECKING THE TRAVEL DEVIATION....................... 30
CONTROL VALVE ....................................................... 32
CONTROL AND REGULATION OF THE SERVOCONTROLPOWER
SUPPLY ....................................... 33
ELIMINATION OF RESIDUAL PRESSURES - PRESSURISATION
OF THE TANK............................................ 35
BLEEDING AIR FROM THE HYDRAULIC CIRCUITS. 36
TRACK TENSION TEST AND ADJUSTMENT ............ 38
30. REMOVAL AND INSTALLATION................................................................................... 30-1
HOW TO READ THE MANUAL .....................................3
PRECAUTIONS TO BE TAKEN WHILE WORKING .....4
ENGINE HOOD...............................................................5
• Removal ....................................................................5
• Installation .................................................................5
CAB ................................................................................6
• Ribaltamento .............................................................6
• Removal ..................................................................10
• Installation ...............................................................13
BATTERY .....................................................................14
• Removal ..................................................................14
• Installation ...............................................................14
STARTING MOTOR .....................................................15
• Removal ..................................................................15
• Installation ...............................................................15
ALTERNATOR .............................................................16
• Removal ..................................................................16
• Installation ...............................................................16
AIR INTAKE FILTER....................................................17
• Removal ..................................................................17
• Installation ...............................................................17
MUFFLER.....................................................................18
• Removal ..................................................................18
• Installation ...............................................................19
VALVE COVER ............................................................20
• Removal ..................................................................20
• Installation ...............................................................20
INJECTORS..................................................................21
• Removal ..................................................................21
• Installation ...............................................................21
INJECTION PUMP........................................................22
• Removal ..................................................................22
• Installation ...............................................................24
CYLINDER HEAD.........................................................25
• Removal ..................................................................25
• Installation ...............................................................27
COOLANT LIQUID PUMP............................................28
• Removal ..................................................................28
• Installation ...............................................................28
RADIATOR GROUP.....................................................29
• Removal ..................................................................29
• Installation ...............................................................30
FUEL TANK..................................................................31
• Removal ..................................................................31
• Installation............................................................... 32
ENGINE-PUMP GROUP.............................................. 33
• Removal.................................................................. 33
• Installation............................................................... 36
COMPLETE HYDRAULIC PUMP................................ 37
• Removal.................................................................. 37
• Installation............................................................... 39
GEAR PUMP................................................................ 40
• Removal.................................................................. 40
• Installation............................................................... 40
ENGINE-PUMP COUPLING........................................ 41
• Removal.................................................................. 41
• Installation............................................................... 41
CONTROL VALVE....................................................... 42
• Removal.................................................................. 42
• Installation............................................................... 42
PPC VALVES............................................................... 43
• Removal.................................................................. 43
• Installation............................................................... 43
BUCKET CYLINDER ................................................... 46
• Removal.................................................................. 46
• Installation............................................................... 47
WORK EQUIPMENT CYLINDERS.............................. 48
• Disassembly ........................................................... 48
• Assembly ................................................................ 50
• Installation............................................................... 56
• Removal.................................................................. 57
• Removal.................................................................. 58
• Installation............................................................... 59
WORKING EQUIPMENT SUPPORT FRAME ............. 60
• Removal.................................................................. 60
• Installation............................................................... 60
HEATING SYSTEM BLOWER FAN............................ 61
• Removal.................................................................. 61
• Installation............................................................... 62
TRACK......................................................................... 63
• Removal.................................................................. 63
• Installation............................................................... 64
LOWER IDLER ROLLER ............................................ 65
• Removal.................................................................. 65
• Installation............................................................... 65
IDLER WHEELS .......................................................... 66
• Removal.................................................................. 66
• Installation............................................................... 66
30-2 CK25-1
DRIVE WHEEL............................................................. 67
• Removal.................................................................. 67
• Installation............................................................... 67
TRACK TENSIONER CYLINDER................................ 68
• Removal.................................................................. 68
• Installation............................................................... 68
FINAL DRIVE ............................................................... 69
• Removal.................................................................. 69
• Installation............................................................... 71
FINAL DRIVE ............................................................... 72
• Disassembly............................................................ 72
• Assembly ................................................................ 84
40. MAINTENANCE STANDARD.......................................................................................... 40-1
P.T.O. ........................................................................................ 2
FRAME AND BUMPER SPRING .............................................. 3
TRACK TENSIONER IDLER WHEEL ....................................... 4
DRIVE WHEEL.......................................................................... 5
LOWER IDLER ROLLERS ........................................................ 6
REAR IDLER WHEEL ............................................................... 7
HYDRAULIC PUMP .................................................................. 8
CONTROL VALVE .................................................................. 10
R.H. PPC VALVE .................................................................... 23
L.H. PPC VALVE ..................................................................... 24
PATTERN CHANGE VALVE (OPTIONAL) ............................. 26
CYLINDERS............................................................................ 27
WORKING EQUIPMENT......................................................... 28
90. OTHER......................................................................................................................90-1
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File Format: PDF
Pages: 306
Printable: Yes
Language: English
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